Stackable container with angled corner panel and container blank

ABSTRACT

A tray-type container includes a bottom wall, longitudinally-extending outer side walls, and laterally-extending end walls, the outer side walls and the end walls extending upwardly from the bottom wall to form an inner cavity. The container includes a corner assembly configured to increase the container stability. The corner assembly includes an angled corner panel that extends across the corner and supplies added stability to the container. The containers may be used singularly, or a plurality of tray-type containers may be unitized in several stacked configurations. Typically, the plurality of unitized containers are placed upon a shipping pallet or slip sheet, or placed within a shipping container to facilitate shipping by large carriers.

FIELD OF THE INVENTION

This invention relates generally to shipping and display type containershaving angled corner panels.

BACKGROUND OF THE INVENTION

Cartons or containers formed from folded corrugated paperboard orsimilar flat sheet stock material are often stacked on one anotherduring shipping and storage of products. In high volume retail stores,product is not only stored in stacked cartons, but frequently ispresented to consumers in that form, e.g., with the stacked cartonsdisposed on pallets. Stacking is obviously efficient as to the use ofspace and pallets enable a number of cartons to be handled as a unit.

Containers in stacks are subjected to various forces, not limited tovertical compression due to the weight of containers over them in astack. Such forces (as well as vertical compressive forces) areaggravated by handling, for example transport of a stack on a pallet,manual handling of one or more containers in a stack, etc. Tensionand/or compression applied in various directions to the container wallscan be sufficient to wholly or partly collapse a container or laterallyto deflect, bend or fold the vertically oriented walls of the container.The result is a reduction of structural integrity, and may includecrushing or other damage to the container contents. In addition, whenthe walls of one or more containers in a stack are crushed, wholly orpartly collapsed, or otherwise deformed, the deformed container may nolonger provide a stable horizontal support for containers stacked overit. The overlying stack may then tip laterally. A leaning “tower” ofcontainers may fall, and even if there is no injury to persons, thecontents of the containers may spill or be damaged.

Apart from instability due to partial collapse of the walls of one ormore containers in a stack, instability leading to spills and possiblecollapse of a stack may be caused by containers being shiftedhorizontally relative to underlying containers. Customer access andtraffic in retail/warehouse stores makes it likely that containers willbe shifted horizontally.

It often is necessary for stock clerks at the warehouse retailer torearrange containers on a pallet as certain containers are emptied, forexample to consolidate product from a number of nearly empty opencartons into one, to restack or reposition the cartons for neatness,etc. It is advantageous if such rearrangement can be accomplished easilyand quickly, especially because stock clerk staffing at warehouseretailers is preferably minimal. Containers stacked on a pallet,however, may be difficult to maneuver easily or quickly, may be stackedin close proximity to each other and may be bulky and cumbersome whenfilled with merchandise. If containers are stacked on open containers,which is sometimes desirable, the stack may have inadequate support.

SUMMARY OF THE INVENTION

In accordance with aspects of the present invention, a single pieceblank for forming a container having an inner cavity is provided. Theblank includes a bottom panel, and an end panel hingedly connected tothe bottom panel by a first fold line. The blank also includes an outerside panel having an outer edge and hingedly connected to the bottompanel by a second fold line. An inner side wall panel is hingedlyconnected to the outer panel. The blank further includes and “L” shapedcorner assembly including a first corner panel, a second corner panel,and angled corner panel and a third corner panel. Still further an endpanel flap is connected with the end panel via an interrupted and spacedapart number of hinge flaps.

In accordance with another aspect of the present invention, a containerincludes a bottom panel, and outer side panels that extend upwardly fromthe bottom panel. The container also includes end panels that extendupwardly from the bottom wall to form, along with the side panels, aninner cavity. The container further includes and “L” shaped cornerassembly with an angled corner panel extending across the containercorner. The corner assembly includes a first corner panel and a secondcorner panel positioned parallel the end panel. Additionally, the cornerassembly includes a third corner panel positioned parallel the outerside panel. The angled corner panel extends across the container cornerbetween the second corner panel and the third corner panel. An end panelflap is also positioned substantially parallel to and engaging with thefirst corner panel and second corner panel.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred and alternative embodiments of the present invention aredescribed in detail below with reference to the following drawings.

FIG. 1 is a perspective view of a container blank formed in accordancewith the present invention;

FIG. 2 is a perspective view of a partially erected container formedfrom the blank of FIG. 1;

FIG. 3 is another perspective view of a partially erected containerformed from the blank of FIG. 1;

FIG. 4 is yet another perspective view of a partially erected containerformed from the blank of FIG. 1; and,

FIG. 5 is a perspective view of a container made from the blank of FIG.1.

DETAILED DESCRIPTION OF THE INVENTION

The present invention includes a single sheet of foldable material cutand scored to form a blank formable into a container having angledcorner walls. By way of overview and with reference to FIGS. 1-5, anembodiment of the present invention includes a single piece blank 20arranged to form a stackable container 50. Specific details of the blank20 and container 50 are described with more particularity below.

The present invention will now be described with reference to theaccompanying FIGS. 1-5 where like numerals correspond to like elements.In all FIGURES, cut lines are shown as solid lines, score lines or linesof weakness are shown as broken lines. The present invention is directedto a tray-type container that utilizes a corner assembly having anangled corner panel coupled with other corner panels to create a modularstackable container. The container includes an arrangement of panels,which are adapted to provide suitable container stability.

One suitable embodiment of the blank 20, constructed in accordance withthe present invention is illustrated in FIGS. 1 and 5. The blank 20 andcontainer 50 include a bottom panel 20, longitudinally-extending outerside walls 26, and laterally-extending end walls 24. A plurality oftray-type containers 50 may be placed upon a shipping pallet or slipsheet (not shown), or placed within a shipping container (not shown) tofacilitate shipping or displaying at a retail location.

For the purpose of further description herein, the downward direction isdefined as the direction perpendicular to bottom panel 22 thatcorresponds to the outer surface of the bottom panel when the container50 has been erected, and the upward direction is defined as thedirection perpendicular to the bottom panel that corresponds to theinner surface of the bottom panel when the container 50 has beenerected.

The blank 20 and resulting container 50 is typically made from anysuitable material used in the shipping, storing or displaying of goods.Suitable, nonlimiting examples of such materials include paperboard,containerboard, cardboard, pasteboard, fiberboard, corrugatedcontainerboard, corrugated paperboard, single wall corrugatedcontainerboard, multiwall corrugated containerboard or a combinationthereof. As best shown in FIG. 1, a blank 20 is stamped out of any ofthese suitable materials and assembled in a manner which can be seen inFIGS. 1-5.

With continued reference to FIG. 1, the blank 20 includes a bottom panel22 of generally rectangular shape having multiple edges. It will beappreciated, however, that the bottom panel 22 may also be of othergeometries, such as, without limitation, square. Unless otherwiseapparent, the term “edges” refers generally to a zone or line ofweakness along which a part can be folded, such as a score line, or acut line. Opposite outer side wall panels 26 are hingedly connected toopposite side edges of the bottom panel 22 along fold lines 21. Theblank 20 further includes end panels 24, which are hingedly connected tothe remaining two opposite edges of the bottom panel 22 along fold lines23. The outer side panels 26 include inner side panels 28, which arehingedly connected to the outer side panels 26, along a fold line 33,opposite the bottom panel 22.

Further, the outer side panels 26 include corner assemblies 46 locatedat opposite ends of outer side wall panels 26, and are hingedlyconnected to the outer side panels 26 along fold lines 27. The foldlines 27 are substantially perpendicular to fold lines 21. The cornerassemblies 46 include a first corner panel 30 connected with the outerside panel 26 along fold line 27. A second corner panel 32 is connectedwith the first corner panel 30 along fold line 29, opposite fold line27. An angled corner panel 34 is connected with the second corner panel32 along fold line 31, opposite fold line 29. Still further, a thirdcorner panel 48 is connected with the angled corner panel 34 along afold line 33. The first corner panel 30 and the second corner panel 32each include a hinge flap notch 38. The hinge flap notch 38 is typicallyformed in an edge that lies substantially perpendicular to fold lines27, 29, and 31. Additionally, the angled corner panel 34 includes alocking tab slot 40. The locking tab slot 40 is generally formed in theangled corner panel 34, adjacent or along fold line 31. Those skilled inthe art will appreciate the locking tab slot 40 is designed to work intandem with the locking tabs 44 (discussed below) in order to help holdthe container 50 in an erect state.

The end panels 24 include end panel flaps 36, which are hingedlyattached to the end panel 24, opposite the bottom panel 22, by hingeflaps 42 along interrupted cut line 31. As depicted in the FIGURES, onlytwo hinge flaps 42 are used, however, it will be appreciated that thepresent invention may include more or fewer hinge flaps 42 withoutexceeding the spirit and scope of the present invention. It will also beappreciated that as the hinge flap notch 38 (discussed in more detailbelow) is configured to receive the hinge flaps 42, if more or fewerhinge flaps 42 are used, then the hinge flap notch 38 will need tochange accordingly. Positioned on an outer edge of the end panel flaps36 are locking tabs 40. Those skilled in that art will appreciate thatthe locking tabs 40 and the locking tab slot 44 are configured tointeract upon formation of the container 50 (discussed in more detailbelow), to lock the container 50 in its assembled form.

Referring now to FIGS. 2-5, one method of constructing the container 50from the blank 20 will be described. In the ensuing description,erecting one side of the containers will be described. However, it willbe appreciated that the other side of the container is formed insubstantially similar steps. The first step begins with the inner sidepanel 28 being folded inwardly, about fold line 33, approximately 180°such that the inner side panel 28 and the outer side panel 26 lieadjacent one another and in parallel planes. Additionally, both thesecond corner panel 32, the angled corner panel 34 and the third cornerpanel 48 are folded inwardly, about fold line 29, approximately 180°such that the second corner panel 32 the angled corner panel 34 and thethird corner panel 48 lie adjacent the first corner panel 30 and aportion of the outer side wall 26. At this point, the outer side wall 26and the third corner panel 48 may be suitably attached to one another,via, an adhesive, tape, or mechanical fastener. Likewise, the firstcorner panel and the second corner panel may also be attached to oneanother in a similar fashion. FIG. 2, best represents the container atthis stage of formation.

With specific reference to FIGS. 3 and 4, additional stages of containerformation are depicted. Specifically, the first corner panel 30 and thesecond corner panel 32 are folded upwardly approximately 90°, about foldlines 27 and 31, respectively. In this manner, the first corner panel 30and the second corner panel 32 lie adjacent one another and lie in aplane that is substantially perpendicular to the angled corner panel 34and outer side wall 26. Additionally, the angled corner panel 34 getsestablished. Specifically, as best seen in FIG. 3, the angled cornerpanel 34 extends across the corner, between the second corner panel 32and the third corner panel 48. Those skilled in the art will appreciatethat the angled corner panel 34 serves to increase overall containerstability. Then the entire wall panel and corner assembly 46 is foldedupwardly along fold line 21 such that the first corner panel 30 and thesecond corner panel 32 lie in a plane parallel to fold line 23.

Further, end panels 24 are then folded upright, along fold line 23,approximately 90° with respect to the bottom wall panel 22, as bestshown in FIG. 4. In this position, the hinge flap notches 38 are alongan upper edge of the end walls of the container 50 are spatiallypositioned to receive hinge flaps 42 when the end panel flap 36 iffolded over the first corner panel 30 and the second corner panel 32 asdepicted in FIG. 5. The locking tabs 44 may then be inserted into thelocking tab slots 40 to help hold the container 50 in an erect position.

In use, container 50 may be filled with product (not shown) and stackedwith one or more other containers 50 on a pallet (not shown) or displayshelf (not shown). In one possible application, a selected number ofcontainers 50 filled with product (not shown) are stacked on pallet (notshown), and pallet (not shown) may be moved from receiving directly tothe display floor of the retailer (perhaps after removing an externalcommon cover, strapping or wrap), where end-user purchasers have accessto the pallet of containers. The individual containers 50 may notinclude covers, tops or lids of corrugated material, instead beingarranged such that the upper containers engage over and cover the nextlower one. The containers 50 are accessed on the display floor andgenerate less waste. Purchasers may select product (not shown) from oneof the open containers 50, generally from those containers at the top ofthe stack. The increased strength of the containers allows thecontainers to better resist vertical collapse or lateral deflectioncaused by the forces of handling and the like. Handholds (not shown)allow containers to be easily manipulated by stock personnel or others,individually or in stacks of two or more.

As another alternative, the container of the invention may also includea top or other means to cover the container. In addition to theadvantages apparent from the foregoing description, the presentinvention improves the container's strength, especially crushed in thevertical direction. A related advantage is that the contents of suchcontainers are less likely to be damaged.

While an embodiment of the invention has been illustrated and described,as noted above, many changes can be made without departing from thespirit and scope of the invention. For example, the blank may alsoinclude other features specified by the customer, such as hand holds,vent holes, grease or moisture barriers and the like without exceedingthe scope of the present invention. Accordingly, the scope of theinvention is not limited by the disclosure of the preferred embodiment.Instead, the invention should be determined entirely by reference to theclaims that follow.

1. A blank for a container comprising: a single sheet of foldablematerial cut and scored to define a bottom panel, said bottom panelhaving a side edge and an end edge; a sidewall panel hingedly attachedto said bottom panel along said side edge, said sidewall panel having afront edge, a first corner panel hingedly attached to said bottom panelalong said front edge; a second corner panel hingedly attached to saidfirst corner panel, opposite said sidewall panel; an angled corner panelhingedly attached to said second corner panel, opposite said firstcorner panel; a third corner panel hingedly attached to said angledcorner panel, opposite said second corner panel, an end panel hingedlyattached to said bottom panel along said end edge; and end panel flaphingedly attached to said end panel along a spaced apart hinge line,opposite said bottom panel.
 2. The blank of claim 1 wherein the blank isformed from at least one of a paperboard, containerboard, cardboard,pasteboard, fiberboard, corrugated containerboard, corrugatedpaperboard, single wall corrugated containerboard, and multiwallcorrugated containerboard.
 3. The blank of claim 1 further comprising aninner sidewall panel hingedly attached to said outer sidewall panel,opposite said bottom panel.
 4. The blank of claim 1 further comprisingfirst a hinge flap notch formed in an outer edge of said first cornerpanel.
 5. The blank of claim 1, wherein said angled corner panel furthercomprises a locking tab slot.
 6. A container comprising: a bottom panel,a side panel extending upwardly from said bottom panel; an end panelextending upwardly from said bottom panel to form, along with said sidepanel, an inner cavity; a first corner panel positioned parallel to theend panel; a second corner panel adjacent the first corner panel; athird corner panel adjacent the outer wall panel; an angled corner panelextending between the second corner panel and the third corner paneland, an end panel flap positioned parallel to the end panel.
 7. Thecontainer of claim 6 wherein the container is formed from at least oneof a paperboard, containerboard, cardboard, pasteboard, fiberboard,corrugated containerboard, corrugated paperboard, single wall corrugatedcontainerboard, and multiwall corrugated containerboard.
 8. Thecontainer of claim 6 further comprising a second sidewall panel adjacentsaid first sidewall panel.
 9. The container of claim 6, wherein saidangled corner panel further comprises a locking tab slot.